Printed wiring board and method for manufacturing the same

ABSTRACT

A printed wiring board includes a base insulating layer, a conductor layer formed on the base layer and including conductor pads, an underlayer formed on one of the conductor pads and including a metal different from a metal of the conductor layer, a solder resist layer formed on the base layer such that the solder resist layer is covering the conductor layer and has openings exposing the conductor pads, and a bump formed directly on a first conductor pad of the conductor pads and including a base plating layer formed in a first opening of the openings and a top plating layer formed on the base plating layer such that a metal of the base plating layer is same as the metal of the conductor layer. The conductor pads include a second conductor pad such that the second conductor pad is the one of the conductor pads having the underlayer.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of and claims the benefit ofpriority to U.S. patent application Ser. No. 17/030,947, filed Sep. 24,2020, which is based upon and claims the benefit of priority to JapanesePatent Application No. 2019-174477, filed Sep. 25, 2019. The entirecontents of these applications are incorporated herein by reference.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a printed wiring board having platingbumps and a method for manufacturing the printed wiring board.

Description of Background Art

Japanese Patent Application Laid-Open Publication No. 2010-129996describes bump formation using a plating method. The entire contents ofthis publication are incorporated herein by reference.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a printed wiring boardincludes a base insulating layer, a conductor layer formed on the baseinsulating layer and including conductor pads, an underlayer formed onone of the conductor pads of the conductor layer and including a metaldifferent from a metal of the conductor layer, a solder resist layerformed on the base insulating layer such that the solder resist layer iscovering the conductor layer and has openings exposing the conductorpads, respectively, and a bump formed directly on a first conductor padof the conductor pads and including a base plating layer formed in afirst opening of the openings and a top plating layer formed on the baseplating layer such that a metal of the base plating layer is same as themetal of the conductor layer.

According to another aspect of the present invention, a method formanufacturing a printed wiring board includes forming a conductor layeron a base insulating layer such that the conductor layer includesconductor pads, forming a solder resist layer on the base insulatinglayer such that the solder resist layer covers the conductor layer andthat the solder resist layer has openings exposing the conductor pads,respectively, forming on one of the conductor pads of the conductorlayer an underlayer including a metal that is different from a metal ofthe conductor layer, and forming directly on a first conductor pad ofthe conductor pads a bump including a base plating layer and a topplating layer. The forming of the bump includes forming the base platinglayer in a first opening of the openings and forming the top platinglayer on the base plating layer such that a metal of the base platinglayer is same as the metal of the conductor layer.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the invention and many of the attendantadvantages thereof will be readily obtained as the same becomes betterunderstood by reference to the following detailed description whenconsidered in connection with the accompanying drawings, wherein:

FIG. 1 is a cross-sectional view illustrating a printed wiring board ofan embodiment of the present invention;

FIG. 2A is a cross-sectional view illustrating a method formanufacturing a printed wiring board according to an embodiment of thepresent invention;

FIG. 2B is a cross-sectional view illustrating the method formanufacturing a printed wiring board according to the embodiment;

FIG. 2C is a cross-sectional view illustrating the method formanufacturing a printed wiring board according to the embodiment;

FIG. 2D is a cross-sectional view illustrating the method formanufacturing a printed wiring board according to the embodiment;

FIG. 2E is a cross-sectional view illustrating the method formanufacturing a printed wiring board according to the embodiment;

FIG. 2F is a cross-sectional view illustrating the method formanufacturing a printed wiring board according to the embodiment;

FIG. 2G is a cross-sectional view illustrating the method formanufacturing a printed wiring board according to the embodiment;

FIG. 2H is a cross-sectional view illustrating the method formanufacturing a printed wiring board according to the embodiment; and

FIG. 3 is a cross-sectional view illustrating a printed wiring boardaccording to a conventional technology.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Embodiments will now be described with reference to the accompanyingdrawings, wherein like reference numerals designate corresponding oridentical elements throughout the various drawings.

Printed Wiring Board

FIG. 1 illustrates an enlarged view of a portion of a printed wiringboard 10 of the embodiment. The printed wiring board 10 may be asubstrate with a core formed by alternately laminating conductor layersand resin insulating layers on one side or both sides of a coresubstrate (not illustrated in the drawings), the conductor layers eachhaving a predetermined circuit pattern. In the case where the conductorlayers are formed on both sides of the core substrate, conductor layersopposing each other via the core substrate may be connected to eachother via through-hole conductors (not illustrated in the drawings).Alternatively, the printed wiring board 10 may be a coreless substrateobtained by alternately laminating conductor layers and resin insulatinglayers on a support plate (not illustrated in the drawings) instead of acore substrate, and then removing the support plate. In any case, asillustrated in FIG. 1 , the printed wiring board 10 includes at least abase insulating layer 12 which is positioned the outermost among theresin insulating layers, a conductor layer 14 which is formed on thebase insulating layer 12 and has a predetermined circuit pattern, and asolder resist layer 16 which is formed on the base insulating layer 12and the conductor layer 14. Other multiple conductor layers and multipleresin insulating layers are often alternately provided below the baseinsulating layer 12, but are omitted in the drawings. However, it isalso possible that the printed wiring board 10 is formed of oneinsulating layer (the base insulating layer 12) and one conductor layer(the conductor layer 14).

The base insulating layer 12 can be formed of, for example, a resincomposition or the like containing an inorganic filler, such as silicaor alumina, and an epoxy resin. The conductor layer 14 is formed of aconductive metal, for example, a metal containing copper as a maincomponent.

The solder resist layer 16 has a first opening (16 a) exposing a portionof the conductor layer 14 as a first conductor pad (14 a), a secondopening (16 b) having a smaller diameter than the first opening (16 a)and exposing another portion of the conductor layer 14 as a secondconductor pad (14 b), and a third opening (16 c) having, for example, alarger diameter than the first opening (16 a) and exposing yet anotherportion of the conductor layer 14 as a third conductor pad (14 c). Anaspect ratio of the first opening (16 a), that is, a ratio of a depth toa diameter at a bottom thereof can be set to 0.5 or less. An aspectratio of the second opening (16 b), that is, a ratio of a depth to adiameter at a bottom thereof can be set to 0.6 or more.

An underlayer 18 is formed on the third conductor pad (14 c). As theunderlayer 18, for example, a nickel layer formed on a surface of thethird conductor pad (14 c), a palladium layer formed on the nickellayer, and a gold layer formed on the palladium layer can beexemplified. In addition, a nickel layer and a gold layer formed on thenickel layer can be exemplified.

The printed wiring board 10 further includes a first bump 20 which isformed on the first conductor pad (14 a), and a second bump 22 which isformed on the second conductor pad (14 b) and has a smaller diameterthan the first bump 20. The first and second bumps (20, 22) arerespectively formed directly on the first and second conductor pads (14a, 14 b) without the underlayer 18. The first bump 20 can be used forconnecting to a power source or a ground line. The second bump 22 havinga smaller diameter than the first bump 20 can be used for connecting toa signal line. The third conductor pad (14 c) can be used, for example,for connecting to a terminal of an electronic component such as acapacitor via the underlayer 18.

The first bump 20 has a first base plating layer 24 formed in the firstopening (16 a), and a first top plating layer 28 formed in asubstantially hemispherical shape on the first base plating layer 24 viaa first intermediate layer 26 containing, for example, nickel as a maincomponent. The first intermediate layer 26 preferably has a thickness of7 μm or less.

The first base plating layer 24 is formed of the same conductive metalas the conductor layer 14, for example, a metal containing copper as amain component. The first base plating layer 24 is formed to a heightexceeding a surface of the solder resist layer 16 (a surface on anopposite side with respect to the base insulating layer 12). As aresult, the first bump 20 is stably held in the first opening (16 a). Aheight measured from the surface of the solder resist layer 16 to anupper end surface (24 a) of the first base plating layer 24 ispreferably in a range of 3 μm-15 μm.

The first top plating layer 28 is formed of a metal which has a lowermelting point than the first base plating layer 24 and which is meltedby a reflow treatment and is shaped into a substantially hemisphericalshape as illustrated in FIG. 1 , for example, a metal containing tin asa main component. A thickness of the first top plating layer 28 (adistance in a vertical direction from a lower end of the first topplating layer 28 to a top of the first top plating layer on an outerperipheral surface of the first bump 20) is preferably set in a range of20 μm-40 μm. By setting the thickness of the first top plating layer 28in this range, good connection reliability can be achieved between thefirst bump 20 and a connection pad (not illustrated in the drawings) ofan electronic component such as a semiconductor chip or a memory mountedon the printed wiring board 10.

The second bump 22 has a second base plating layer 30 formed in thesecond opening (16 b), and a second top plating layer 34 formed in asubstantially hemispherical shape on the second base plating layer 30via a second intermediate layer 32 containing, for example, nickel as amain component. The second intermediate layer 32 preferably has athickness of 7 μm or less.

The second base plating layer 30 is formed of the same conductive metalas the conductor layer 14, for example, a metal containing copper as amain component. The second base plating layer 30 is formed to a heightexceeding the surface of the solder resist layer 16 (the surface on anopposite side with respect to the base insulating layer 12). As aresult, the second bump 22 is stably held in the second opening (16 b).A height measured from the surface of the solder resist layer 16 to anupper end surface (30 a) of the second base plating layer 30 ispreferably in a range of 3 μm-15 μm.

The second top plating layer 34 is formed of a metal which has a lowermelting point than the second base plating layer 30 and which is meltedby a reflow treatment and is shaped into a substantially hemisphericalshape as illustrated in FIG. 1 , for example, a metal containing tin asa main component. A thickness of the second top plating layer 34 (adistance in the vertical direction from a lower end of the second topplating layer 34 to a top of the second top plating layer 34 on an outerperipheral surface of the second bump 22) is preferably set in a rangeof 20 μm-40 μm. By setting the thickness of the second top plating layer34 in this range, good connection reliability can be achieved betweenthe second bump 22 and a connection pad (not illustrated in thedrawings) of an electronic component such as a semiconductor chip or amemory mounted on the printed wiring board 10.

In the printed wiring board 10 of the embodiment shown in FIG. 1 , thefirst base plating layer 24 and the second base plating layer 30 areformed together, and the upper end surface (24 a) of the first baseplating layer 24 and the upper end surface (30 a) of the second baseplating layer 30 have the same height as each other. Further, the firstintermediate layer 26 and the second intermediate layer 32 are formedtogether and have the same thickness (height) as each other.

Then, the first top plating layer 28 and the second top plating layer 34are formed together and are adjusted in their metal plating amounts andhave the same thickness (height) as each other after melting by a reflowtreatment.

As a result, in the printed wiring board 10 of the embodimentillustrated in FIG. 1 , even when the bumps (20, 22) of different sizesare provided, the bump 20 and the bump 22 have substantially the same inheight. In addition, the first and second base plating layers (24, 30)are formed of the same conductive metal as the conductor layer 14forming the first and second conductor pads (14 a, 14 b), for example, ametal containing copper as a main component, and are respectivelydirectly formed on the first and second conductor pads (14 a, 14 b).Therefore, the base plating layers (24, 30) and thus the first andsecond bumps (20, 22) have sufficiently high connection reliability withrespect to the conductor pads (14 a, 14 b).

Method for Manufacturing Printed Wiring Board

In the following, a method for manufacturing a printed wiring boardaccording to an embodiment of the present invention is described withreference to FIGS. 2A-2H for manufacturing the printed wiring board 10illustrated in FIG. 1 .

FIG. 2A illustrates an intermediate in which the conductor layer 14 andthe solder resist layer 16 are formed on the base insulating layer 12using a common method, the conductor layer 14 having a predeterminedcircuit pattern. Other multiple conductor layers and multiple resininsulating layers are often alternately formed below the base insulatinglayer 12, but are omitted in the drawings. The multiple conductor layersand the multiple resin insulating layers can be laminated on a coresubstrate or on a support plate that can be removed afterwards. However,it is also possible that the printed wiring board 10 is formed from oneresin insulating layer as the base insulating layer 12 and one conductorlayer as the conductor layer 14. In this case, the resin insulatinglayer corresponds to the base insulating layer 12. For the baseinsulating layer 12, an insulating resin film for a build-up layercontaining inorganic filler such as silica or alumina and an epoxy resincan be used.

As illustrated in FIG. 2B, the third opening (16 c) exposing a portionof the conductor layer 14 as the third conductor pad (14 c) is firstformed in the solder resist layer 16 using, for example, CO₂ laser,UV-YAG laser, or the like.

As illustrated in FIG. 2C, the underlayer 18 is formed on the thirdconductor pad (14 c), for example, by laminating a nickel layer, apalladium layer, and a gold layer in this order by plating.

As illustrated in FIG. 2D, next, the first opening (16 a) exposinganother portion of the conductor layer 14 as the first conductor pad (14a) and the second opening (16 b) exposing yet another portion of theconductor layer 14 as the second conductor pad (14 b) are formed in thesolder resist layer 16, for example, using CO₂ laser, UV-YAG laser orthe like.

As illustrated in FIG. 2E, for example, an electroless plating treatmentsuch as an electroless copper plating treatment is performed, and a seedlayer 36 is formed on the surface of the solder resist layer 16 of theintermediate, on side surfaces of the first, second and third openings(16 a, 16 b, 16 c), and on the conductor pads (14 a, 14 b).

As illustrated in FIG. 2F, a plating resist 38 of a predeterminedpattern that is formed of, for example, a dry film resist and hasopenings (38 a, 38 b) at planned formation sites of the first and secondbumps (20, 22) (FIG. 1 ) is formed on the seed layer 36.

As illustrated in FIG. 2G, an electrolytic plating treatment isperformed, and the first base plating layer 24 and the second baseplating layer 30, which contain a conductive metal of the same kind asthe conductor layer 14 forming the first and second conductor pads (14a, 14 b), for example, copper as a main component, are formed onportions of the seed layer 36 exposed in the openings (38 a, 38 b) ofthe plating resist 38 (including portions of the seed layer 36 in firstand second openings (16 a, 16 b) of the solder resist layer 16 andremaining exposed portions of the seed layer 36 in the openings (38 a,38 b) of the plating resist 38). The heights measured from the surfaceof the solder resist layer 16 to the upper end surfaces (24 a, 30 a) ofthe first and second base plating layers (24, 30) are substantially thesame.

As illustrated in FIG. 2G, further, for example, an electrolytic platingtreatment is performed, and the first and second intermediate layers(26, 32) containing, for example, nickel as a main component are formedon the upper end surfaces (24 a, 30 a) of the first and second baseplating layers (24, 30) in the openings (38 a, 38 b) of the platingresist 38. The thicknesses of the first and second intermediate layers(26, 32) are each preferably 7 μm or less, and are substantially thesame as each other.

As illustrated in FIG. 2G, further, for example, an electrolytic platingtreatment is performed, and the first and second top plating layers (28,34) are formed on the upper end surfaces (24 a, 30 a) of the first andsecond base plating layers (24, 30) in the openings (38 a, 38 b) of theplating resist 38 with the first and second intermediate layers (26, 32)interposed therebetween. The first and second top plating layers (28,34) are each formed of a metal which has a lower melting point than thefirst and second base plating layers (24, 30) and which is melted by areflow treatment and is shaped into a substantially hemispherical shape,for example, a metal containing tin as a main component. The heights ofthe first and second top plating layers (28, 34) after a reflowtreatment are preferably each in a range of 20 μm-40 μm and aresubstantially the same as each other.

As illustrated in FIG. 2H, the plating resist 38 is peeled off. Further,a portion of the seed layer 36 exposed by the removal of the platingresist 38 is removed by etching.

As illustrated in FIG. 1 , a reflow treatment is performed, and thefirst top plating layer 28 and the second top plating layer 34 areshaped into substantially hemispherical shapes. Due to the reflowtreatment, the first bump 20 and second bump 22 are formed eachincluding, from a side close to the first and second conductor pads (14a, 14 b), for example, a copper base plating layer, a nickelintermediate layer, and a tin top plating layer, and the heights of thefirst and second bumps (20, 22) are substantially the same as eachother. In FIG. 1 , illustration of the seed layer 36 is omitted.

Further, the first and second base plating layers (24, 30) are formed ofthe same conductive metal as the conductor layer 14 forming the firstand second conductor pads (14 a, 14 b), for example, a metal containingcopper as a main component, and are respectively directly formed on thefirst and second conductor pads (14 a, 14 b). Therefore, the baseplating layers (24, 30) and thus the first and second bumps (20, 22)have sufficiently high connection reliability with respect to theconductor pads (14 a, 14 b).

As illustrated in FIG. 3 , when plating bumps (20′, 22′) are formed byforming a conductor layer (14′) on a base insulating layer (12′) of aprinted wiring board (10′), forming a solder resist layer (16′) on thebase insulating layer (12′) and the conductor layer (14′), respectivelyforming base plating layers (24′, 30′) via an underlayer (18′) onconductor pads (14 a′, 14 b′) in openings (16 a′, 16 b′) formed in thesolder resist layer (16′), and respectively forming top plating layers(28′, 34′) via intermediate layers (26′, 32′) on the base plating layers(24′, 30′), since the underlayer (18′) is formed of a metal differentfrom those of the conductor pads (14 a′, 14 b′) and the base platinglayers (24′, 30′), there is a problem that the base plating layers (24′,30′) cannot have a sufficiently high connection reliability with respectto the conductor pads (14 a′, 14 b′).

A printed wiring board according to an embodiment of the presentinvention includes: a base insulating layer; a conductor layer that isformed on the base insulating layer and includes conductor pads; anunderlayer that is formed on one of the conductor pads of the conductorlayer and includes a metal different from a metal of the conductorlayer; a solder resist layer that is formed on the base insulating layerand on the conductor layer and has openings exposing portions of theconductor layer as conductor pads, respectively; a bump that is directlyformed on a first conductor pad of the conductor pads. The bump has: abase plating layer that is formed in a first opening of the openings andis formed of the same metal as the conductor layer; and a top platinglayer that is formed on the base plating layer.

Further, a method for manufacturing a printed wiring board according toan embodiment of the present invention includes: forming a conductorlayer on a base insulating layer such that the conductor layer includesconductor pads; forming a solder resist layer on the base insulatinglayer such that the solder resist layer covers the conductor layer andthat the solder resist layer has openings exposing the conductor pads,respectively; forming on one of the conductor pads of the conductorlayer an underlayer including a metal that is different from a metal ofthe conductor layer; and forming directly on a first conductor pad ofthe conductor pads a bump including a base plating layer and a topplating layer. The forming of the bump includes forming the base platinglayer in a first opening of the openings and forming the top platinglayer on the base plating layer such that a metal of the base platinglayer is same as the metal of the conductor layer.

Obviously, numerous modifications and variations of the presentinvention are possible in light of the above teachings. It is thereforeto be understood that within the scope of the appended claims, theinvention may be practiced otherwise than as specifically describedherein.

What is claimed is:
 1. A printed wiring board, comprising: a baseinsulating layer; a conductor layer formed on the base insulating layerand including a plurality of conductor pads; a solder resist layerformed on the base insulating layer such that the solder resist layer iscovering the conductor layer and has a plurality of openings exposingthe plurality of conductor pads, respectively; a bump formed directly ona first conductor pad of the plurality of conductor pads and comprisinga base plating layer and a top plating layer formed on the base platinglayer; and an underlayer formed directly on a second conductor pad ofthe plurality of conductor pads in the conductor layer and comprising ametal different from a metal of the conductor layer, wherein the bump isformed such that the base plating layer is formed in an opening of theplurality of openings and that a metal of the base plating layer is sameas the metal of the conductor layer, and a bump that is same as the bumpformed on the first conductor pad is not formed on the underlayer on thesecond conductor pad.
 2. The printed wiring board according to claim 1,wherein each of the metals of the conductor layer and the base platinglayer of the bump includes a main component comprising copper.
 3. Theprinted wiring board according to claim 1, wherein the bump includes anintermediate layer comprising a nickel layer and formed between the baseplating layer and the top plating layer.
 4. The printed wiring boardaccording to claim 1, wherein the top plating layer of the bumpcomprises a main component comprising tin.
 5. The printed wiring boardaccording to claim 1, wherein the underlayer includes a nickel layer, apalladium layer and a gold layer such that the nickel layer, thepalladium layer and the gold layer are sequentially laminated.
 6. Theprinted wiring board according to claim 1, wherein the underlayerincludes a nickel layer and a gold layer such that the nickel layer andthe gold layer are sequentially laminated.
 7. The printed wiring boardaccording to claim 2, wherein the bump includes an intermediate layercomprising a nickel layer and formed between the base plating layer andthe top plating layer.
 8. The printed wiring board according to claim 2,wherein the top plating layer of the bump comprises a main componentcomprising tin.
 9. The printed wiring board according to claim 2,wherein the underlayer formed on the second conductor pad includes anickel layer, a palladium layer and a gold layer such that the nickellayer, the palladium layer and the gold layer are sequentiallylaminated.
 10. The printed wiring board according to claim 2, whereinthe underlayer formed on the second conductor pad includes a nickellayer and a gold layer such that the nickel layer and the gold layer aresequentially laminated.
 11. The printed wiring board according to claim3, wherein the top plating layer of the bump comprises a main componentcomprising tin.
 12. The printed wiring board according to claim 7,wherein the top plating layer of the bump comprises a main componentcomprising tin.
 13. A method for manufacturing a printed wiring board,comprising: forming a conductor layer on a base insulating layer suchthat the conductor layer includes a plurality of conductor pads; forminga solder resist layer on the base insulating layer such that the solderresist layer covers the conductor layer and that the solder resist layerhas a plurality of openings exposing the plurality of conductor pads,respectively; forming directly on a first conductor pad of the pluralityof conductor pads a bump comprising a base plating layer and a topplating layer; and forming directly on a second conductor pad of theplurality of conductor pads an underlayer comprising a metal that isdifferent from a metal of the conductor layer, wherein the forming ofthe bump includes forming the base plating layer in an opening of theplurality of openings and forming the top plating layer on the baseplating layer such that a metal of the base plating layer is same as themetal of the conductor layer, and a bump that is same as the bump formedon the first conductor pad is not formed on the underlayer on the secondconductor pad.
 14. The method for manufacturing a printed wiring boardaccording to claim 13, wherein the forming of the bump includesreflowing the top plating layer such that the top plating layer forms asubstantially hemispherical shape.
 15. The method for manufacturing aprinted wiring board according to claim 13, wherein the forming of thesolder resist layer comprises forming a second opening of the pluralityof openings such that the second opening exposes the second conductorpad of the plurality of conductor pads, and forming the opening of theplurality of openings after the forming of the second opening of theplurality of openings such that the base plating layer of the bump isformed in the opening, and the forming of the underlayer comprisesforming the underlayer before the forming of the opening of theplurality of openings in the solder resist layer.
 16. The method formanufacturing a printed wiring board according to claim 13, wherein eachof the metals of the conductor layer and the base plating layer of thebump includes a main component comprising copper.
 17. The method formanufacturing a printed wiring board according to claim 13, wherein theforming of the bump includes forming an intermediate layer comprising anickel layer such that the intermediate layer is interposed between thebase plating layer and the top plating layer.
 18. The method formanufacturing a printed wiring board according to claim 13, wherein thetop plating layer of the bump comprises a main component comprising tin.19. The method for manufacturing a printed wiring board according toclaim 13, wherein the forming of the underlayer on the second conductorpad includes forming a nickel layer, a palladium layer and a gold layersuch that the nickel layer, the palladium layer and the gold layer aresequentially laminated.
 20. The method for manufacturing a printedwiring board according to claim 13, wherein the forming of theunderlayer on the second conductor pad includes forming a nickel layerand a gold layer such that the nickel layer and the gold layer aresequentially laminated.